Mattresses with stabilized upper surfaces

Abstract

A mattress assembly with a surface that is stabilized to prevent separation of rails (e.g., side rails, end rails) from edges of a primary cushion of the mattress assembly. A strip of scrim fabric may overlap each rail and an adjacent portion of the primary cushion to stabilize the interface or seam between an edge of the primary cushion and a rail positioned against that edge. Methods for stabilizing the upper surfaces of mattress assemblies are also disclosed, as are adjustable beds including mattresses with stabilized upper surfaces.

What is claimed: 
     
         1 . A mattress assembly, comprising:
 a primary cushion including an upper surface, a lower surface opposite from the upper surface, and a periphery including a first end edge, a second end edge, and side edges;   a side rail adjacent to each side edge of the side edges of the primary cushion, each side rail including an upper surface that is substantially flush with the upper surface of the primary cushion; and   a strip of scrim fabric positioned over the upper surface of each side rail and over a side portion of the upper surface of the primary cushion adjacent to the side rail, each strip of scrim fabric secured to the side portion of the upper surface of the primary cushion and secured to the upper surface of the side rail.   
     
     
         2 . The mattress assembly of  claim 1 , wherein an outer side edge of the strip of scrim fabric is positioned over or adjacent to an outer edge of the side rail and an inner side edge of the strip of scrim fabric is positioned over the side portion of the primary cushion. 
     
     
         3 . The mattress assembly of  claim 2 , wherein the inner side edge of the strip of scrim fabric is located about 2 inches to about 6 inches interior to the side edge of the primary cushion. 
     
     
         4 . The mattress assembly of  claim 1 , wherein the strip of scrim fabric does not extend over a central portion of the primary cushion. 
     
     
         5 . The mattress assembly of  claim 1 , wherein the strip of scrim fabric is adhered to the side rail. 
     
     
         6 . The mattress assembly of  claim 1 , wherein the primary cushion comprises an elastomeric gel. 
     
     
         7 . The mattress assembly of  claim 6 , wherein the strip of scrim fabric is melt bonded to the primary cushion. 
     
     
         8 . The mattress assembly of  claim 7 , wherein a material of the primary cushion impregnates the strip of scrim fabric. 
     
     
         9 . The mattress assembly of  claim 1 , further comprising:
 a first end rail adjacent to the first end edge of the primary cushion, a first end of the strip of scrim fabric extending over and secured to the first end rail.   
     
     
         10 . The mattress assembly of  claim 9 , further comprising:
 a second end rail adjacent to the second end edge of the primary cushion, a second end of the strip of scrim fabric extending over and secured to the second end rail.   
     
     
         11 . A method for assembling a mattress, comprising:
 positioning a strip of scrim fabric over an interface between a side edge of a primary cushion and a side rail adjacent to the side edge of the primary cushion, an upper surface of the side rail being substantially flush with an upper surface of the primary cushion;   securing the strip of scrim fabric to the upper surface of the side rail; and   securing the strip of scrim fabric to the upper surface of the primary cushion.   
     
     
         12 . The method of  claim 11 , wherein positioning the strip of scrim fabric comprises positioning an outer side edge of the strip of scrim fabric over or adjacent to an outer edge of the side rail and positioning an inner side edge of the strip of scrim fabric over the side portion of the primary cushion. 
     
     
         13 . The method of  claim 12 , wherein positioning the strip of scrim fabric comprises positioning the inner side edge of the strip of scrim fabric about 2 inches to about 6 inches interior to the side edge of the primary cushion. 
     
     
         14 . The method of  claim 11 , wherein positioning the strip of scrim fabric comprises leaving a central portion of the primary cushion exposed beyond the strip of scrim fabric. 
     
     
         15 . The method of  claim 11 , wherein securing the strip of scrim fabric comprises gluing the strip of scrim fabric to the upper surface of the side rail. 
     
     
         16 . The method of  claim 11 , wherein the primary cushion comprises an elastomeric gel. 
     
     
         17 . The method of  claim 16 , wherein securing the strip of scrim fabric to the upper surface of the primary cushion comprises melt bonding the strip of scrim fabric to the upper surface of the primary cushion. 
     
     
         18 . The method of  claim 17 , wherein melt bonding comprises heating the upper surface of the primary cushion through the scrim fabric to a temperature that causes a material at the upper surface of the primary cushion to melt and wick into the strip of scrim fabric. 
     
     
         19 . The method of  claim 11 , wherein securing the strip of scrim fabric to the upper surface of the side rail and securing the strip of scrim fabric to the upper surface of the primary cushion occur concurrently. 
     
     
         20 . The method of  claim 11 , wherein positioning the strip of scrim fabric includes positioning at least one end portion of the strip of scrim fabric at over a portion of at least one end rail adjacent to an end of the primary cushion and an end of the side rail, and further comprising:
 securing the strip of scrim fabric to the portion of the at least one end rail.   
     
     
         21 . The method of  claim 20 , wherein:
 positioning the strip of scrim fabric includes positioning end portions of the strip of scrim fabric over portions of end rails adjacent to each end of the primary cushion; and   securing the strip of scrim fabric to the at least one end rail comprises securing the portions of the end rails.